Swellable compositions, articles formed therefrom, and methods of manufacture thereof

1. A swellable composition comprising:

a matrix material; and

a condensed expandable graphite material disposed in the matrix material;

wherein the condensed expandable graphite material has a bulk density of about 1 to about 8 g/cm 3 and comprises expandable graphite.

2. The composition of claim 1 , wherein the matrix material is one or more of the following: an ethylene-propylene-diene monomer rubber; a butadiene rubber; a styrene-butadiene rubber; a natural rubber; an acrylonitrile butadiene rubber; a styrene-butadiene-acrylonitrile resin; a butadiene-nitrile rubber; a polyisoprene rubber; an acrylate-butadiene rubber; a polychloroprene rubber; an acrylate-isoprene rubber; an ethylene-vinyl acetate rubber; a polypropylene oxide rubber; a polypropylene sulfide rubber; a fluoroelastomer; or a thermoplastic polyurethane rubber.

3. The composition of claim 1 , wherein the condensed expandable graphite material further comprises a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or a metal alloy; wherein the metal is one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

4. The composition of claim 3 , wherein the condensed expandable graphite material comprises about 20 to about 95 wt. % of the expandable graphite and about 5 to about 80 wt. % of the binder.

5. The composition of claim 1 , wherein the condensed expandable graphite material comprises particles having an average particle size of about 10 microns to about 5 centimeters.

6. The composition of claim 1 , further comprising an activation material containing one or more of the following: a thermite; Al—Ni; Ti—Si; Ti—B; Zr—Si, Zr—B; Ti—Al; Ni—Mg; or Mg—Bi.

7. The composition of claim 6 , wherein the thermite comprises a reducing agent and an oxidizing agent, wherein the reducing agent comprises one or more of the following: aluminum; magnesium; calcium; titanium; zinc; silicon; or boron; and the oxidizing agent comprises one or more of the following: boron oxide; silicon oxide; chromium oxide; manganese oxide; iron oxide; copper oxide; or lead oxide.

8. An article comprising the composition of claim 1 .

9. The article of claim 8 , wherein the article is a swellable article.

10. The article of claim 8 , wherein the article is a seal; a high pressure beaded frac screen plug; a screen basepipe plug; a coating for balls and seats; a gasket; a compression packing element; an expandable packing element; an O-ring; a bonded seal; a bullet seal; a sub-surface safety valve seal; a sub-surface safety valve flapper seal; a dynamic seal; a V-ring; a back-up ring; a drill bit seal; a liner port plug; an atmospheric disc; an atmospheric chamber discs; a debris barrier; a drill in stim liner plug; an inflow control device plug; a flapper; a seat; a ball seat; a direct connect disk; a drill-in linear disk; a gas lift valve plug; a fluid loss control flapper; an electric submersible pump seal; a shear out plug; a flapper valve; a gaslift valve; or a sleeve.

11. A seal arrangement comprising:

a swellable member and a sealing member disposed on a surface of the swellable member;

wherein the swellable member comprises a condensed expandable graphite material;

and wherein the condensed expandable graphite material has a bulk density of about 1 to about 8 g/cm 3 and comprises expandable graphite.

12. The seal arrangement of claim 11 , wherein the sealing member comprises one or more of the following: an ethylene-propylene-diene monomer rubber; a butadiene rubber; a styrene-butadiene rubber; a natural rubber; an acrylonitrile butadiene rubber; a styrene-butadiene-acrylonitrile resin; a butadiene-nitrile rubber; a polyisoprene rubber; an acrylate-butadiene rubber; a polychloroprene rubber; an acrylate-isoprene rubber; an ethylene-vinyl acetate rubber; a polypropylene oxide rubber; a polypropylene sulfide rubber; a fluoroelastomer; or a thermoplastic polyurethane rubber.

13. The seal arrangement of claim 11 , wherein the condensed expandable graphite material further comprises a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or a metal alloy; wherein the metal is one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

14. The seal arrangement of claim 13 , wherein the condensed expandable graphite material comprises about 20 to about 95 wt. % of the expandable graphite and about 5 to about 80 wt. % of the binder based on the total weight of the condensed expandable graphite material.

15. The seal arrangement of claim 14 , wherein the condensed expandable graphite material comprises about 20 to about 50 wt. % of the binder based on the total weight of the condensed expandable graphite material.

16. The seal arrangement of claim 13 , wherein the binder comprises copper, nickel, chromium, iron, titanium, an alloy of copper, an alloy of nickel, an alloy of chromium, an alloy of iron, an alloy of titanium, or a combination comprising at least one of the foregoing metal or metal alloy.

17. The seal arrangement of claim 11 , wherein the swellable member further comprises an activation material containing one or more of the following: a thermite; Al—Ni; Ti—Si; Ti—B; Zr—Si, Zr—B; Ti—Al; Ni—Mg; or Mg—Bi.

18. The seal arrangement of claim 17 , wherein the thermite comprises a reducing agent and an oxidizing agent, wherein the reducing agent comprises one or more of the following: aluminum; magnesium; calcium; titanium; zinc; silicon; or boron; and the oxidizing agent comprises one or more of the following: boron oxide; silicon oxide; chromium oxide; manganese oxide; iron oxide; copper oxide; or lead oxide.

19. The seal arrangement of claim 11 , further comprising an extrusion prevention member adjacent the sealing member.

20. The seal arrangement of claim 19 , wherein the extrusion prevention member is a back-up ring.

21. The seal arrangement of claim 11 , wherein the seal arrangement further comprises an annular body; and the swellable member is disposed on a surface of the annular body.

22. The seal arrangement of claim 21 , wherein the annular body is a production tubing.

23. The seal arrangement of claim 11 , wherein the condensed expandable graphite material comprises particles having an average particle size of about 10 microns to about 5 centimeters.

24. A method of deploying a seal arrangement, the method comprising:

positioning a seal arrangement at a predetermined location; the swellable member having a first shape; and

activating the swellable member to cause the swellable member to attain a second shape different from the first shape,

the seal arrangement comprising: a swellable member and a sealing member disposed on a surface of the swellable member; wherein the swellable member comprises a condensed expandable graphite material, and wherein the condensed expandable graphite material has a bulk density of about 1 to about 8 g/cm 3 and comprises expandable graphite.

25. The method of claim 24 , wherein the activating comprises exposing the composition to one or more of the following: a microwave energy; electric current; an electromagnetic radiation; or heat.

26. The method of claim 24 comprising deploying the seal arrangement in a wellbore to isolate or complete the wellbore.

27. The method of claim 24 further comprising disposing a microwave source in the vicinity of the seal arrangement, wherein the microwave source is effective to generate a microwave energy to heat and expand the swellable member.

28. The method of claim 24 , wherein the seal arrangement further comprises an annular body; and the swellable member is disposed on a surface of the annular body.

29. The method of claim 28 , further comprising disposing a microwave source in the annular body.

30. The method of claim 24 , wherein the sealing member comprises one or more of the following: an ethylene-propylene-diene monomer rubber; a butadiene rubber; a styrene-butadiene rubber; a natural rubber; an acrylonitrile butadiene rubber; a styrene-butadiene-acrylonitrile resin; a butadiene-nitrile rubber; a polyisoprene rubber; an acrylate-butadiene rubber; a polychloroprene rubber; an acrylate-isoprene rubber; an ethylene-vinyl acetate rubber; a polypropylene oxide rubber; a polypropylene sulfide rubber; a fluoroelastomer; or a thermoplastic polyurethane rubber.

31. The method of claim 24 , wherein the condensed expandable graphite material further comprises a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or a metal alloy; wherein the metal is one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

32. The method of claim 24 , wherein the swellable member further comprises an activation material containing one or more of the following: a thermite; Al—Ni; Ti—Si; Ti—B; Zr—Si, Zr—B; Ti—Al; Ni—Mg; or Mg—Bi.

33. The method of claim 24 , further comprising an extrusion prevention member adjacent the sealing member.

34. The method of claim 24 , wherein the extrusion prevention member is a back-up ring.

35. The method of claim 24 , wherein the seal arrangement further comprises an annular body; and the swellable member is disposed on a surface of the annular body.